Metal wall frame assembly

ABSTRACT

A pre-cut and pre-measured system for building a metal wall frame is disclosed translated directly from architectural plans of the wall assembly. The metal wall frame includes a track member and a stud member, where the stud member contains a pair of dimples located on either end portion. The pair of dimples nests into an associated pair of indent portions located in the track member. The location of the indent portions and dimple portions are determined by an architectural plan, reducing installation time. The stud and track members come pre-cut to length in bundles connected with metal nips, eliminating the need for any shearing or cutting of the metal pieces.

This application is a continuation-in-part of and claims priority to U.S. application Ser. No. 14/879,411, filed on Oct. 9, 2015, which claims the benefit of U.S. Provisional Patent Application No. 62/062,438 filed on Oct. 10, 2014. This application also claims the benefit of U.S. Provisional Patent Application No. 62/245,597 filed on Oct. 23, 2015. The contents of the foregoing applications are incorporated by reference in their entirety.

BACKGROUND AND SUMMARY

The present disclosure is related to a novel metal wall frame assembly system. Previously, metal wall frame assemblies were constructed on-site by separately measuring and cutting to size each metal component of the wall frame assembly with saws, shears, or other similar tools. Given the lengths of starting material, the prior methods created excess material that would be thrown away. The sized metal components were then placed in a measured position in the wall assembly with track members in position along the floor and ceiling, and vertical metal studs placed at desired spaced locations. Finally, the track members and metal studs were secured in position with a screw. This method required the metal stud to be supported in position while drilling and securing the assembly with fasteners. This wall assembly was compounded when one or more doors and/or windows were part of the wall assembly, requiring a large number of custom-cut smaller metal components.

There was a need for a metal wall frame assembly method and system that allowed for translation of architectural plans into a wall assembly system with reduced man hours and end-waste material. The present invention provides for sizing the components of a customized wall assembly directly from architectural plans at a factory using an automated system, bundling of at a factory, partially cutting the components into larger pieces and smaller pieces partially cut to facilitate separation and assembly for convenient transportation to a building site, and assembling the assembly at the construction site with substantially reduced man-hours and end-waste material. A label (e.g., etching, ink-print, or sticker) may be placed on all or selected components enabling the identification of the proper location for each part during assembly of the wall system. Accordingly, the metal wall may be rapidly assembled in the field with precision and without the need for measuring and cutting with minimal assembling time or expertise.

Disclosed is a wall assembly comprising track members each having a web portion and flange portions, with indent portions at selected increments along at least one flange portion of each track member, a plurality of metal studs each having end portions to engage track members and dimpled portions adapted to engage flange portions of track members, and each metal stud having flange portions oriented to engage flange portions of track members with dimpled portions nested with indent portions in the track members at end portions when assembled. The indent portions and dimpled portions are placed in precise locations on each component at the time of making each component in the factory from an architectural plan of the wall assembly, so that the wall assembly can be rapidly assembled in the field.

If desired, at least some of the dimpled portions on components are slotted to provide for adjustment, particularly of stud components in relation to the assembled track members.

The studs, track members and other components of the wall assembly may be cut to length and shorter lengths pre-partially cut automatically following an architectural plan of the desired wall assembly but with such shorter lengths maintained in bundled longer lengths so that bundles can be readily and efficiently transported to an assembly location and the pre-partially cut lengths then separated for assembly of the wall system. The flanges of the studs may be cut as desired with only a small portion left to be separated by cutting or other means in the field.

Specifically, the wall assembly where the studs and track members are pre-partially cut through in shorter lengths in accordance with the desired wall assembly but maintained in longer lengths so that bundles of such studs can be sent to an assembly location and the pre-partially cut lengths separated for assembly of the wall system.

A kit for a wall assembly is also disclosed comprising of track members adapted to be assembled in a wall structure, each having a web portion and indent portions in at least one flange portion of each track member at locations translated directly from an architectural plan of a desired assembled wall structure, a plurality of metal studs each having end portions adapted to engage the track members and with dimpled portions adapted to be assembled nested with indented portions of the track members in accordance with the architectural plan, and each stud having flange portions oriented to engage flange portions of track members of the wall assembly with dimpled portions adapted to nest with indent portions in the track members when assembled in accordance with the architectural plan.

In the kit for a wall assembly, slots may be provided in the flanges of the studs with only at least a part web portion of the studs not precut.

The kit for a wall assembly where in addition the stud lengths are pre-cut to length and shorter lengths partially cut through in accordance to an architectural plan of the desired wall assembly but maintained in longer lengths so that bundles of such studs can be sent to an assembly location and the pre-partially cut lengths separated for assembly of the wall system. The components of the kit for the wall assembly may in addition include slots that are cut through the flanges of the studs and other components to allow for adjustment during assembly in the field.

The kit for wall assembly with the studs pre-partially cut through in shorter lengths in the factory can be maintained in longer lengths so that bundles of such components can be sent to an assembly location and the precut lengths separated during assembly of the wall assembly in accordance with the architectural plans.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a prior art wall assembly component;

FIG. 2 is an overview of a completed wall assembly in accordance with the present invention;

FIG. 3 is a track member with pairs of circular indent portions located at predetermined intervals in accordance with the present invention;

FIG. 4 is metal stud member with a pair of elongated dimple portions on each end portion in accordance with the present invention;

FIG. 5 is a metal stud member with a pair of slotted elongated dimple portions on each end portion in accordance with the present invention;

FIG. 6 is an overview of how two pre-cut metal stud members with circular indent portions are attached during shipping and prior to assembly in accordance with the present invention;

FIG. 7 is a detailed view of the attachment nip between two metal stud members in accordance with the present invention;

FIG. 8 is a front view of a metal stud showing the depth of the pair of dimple portions in accordance with the present invention;

FIG. 9 is a track member with two pre-cut slots seated with two metal studs in accordance with the present invention;

FIG. 10 shows a stud member with elongated dimple portions seated in a track member with circular dimple portions with a hole in accordance with the present invention;

FIG. 11 is cross section of a track member seating with stud member via a shoulder screw in accordance with the present invention;

FIG. 12 is a metal stud member with elongated indent portions meshing with a track member with elongated slotted dimple portions in accordance with the present invention;

FIG. 13 is a track member seated with two stud assemblies, the first seated with an elongated dimple portion and another stud seated with a circular dimple portion in accordance with the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

Presently disclosed is pre-cut and pre-measured assembly kit for the installation of a metal-studded wall. The invention enables a rapid assembly of a pre-cut metal wall components, accomplished through the select placement of indents, dimples, and slots along the length of both the metal studs and track members. The positions of the indents, dimples, and slots as well as the lengths of the metal studs, track members and support beams are directly taken from architectural plans using unique software and manufacturing equipment. By partially cutting through a stock material at specific lengths, multiple components are formed while attached to one another, enabling any number of components to be shipped in a convenient bundle and separated onsite.

Referring to FIG. 1, a prior art track member 10 is illustrated. The track member 10 has two ends 12, a pair of vertical flanges 14, and a web 16, all forming a general “U” shaped structure. Cut into each vertical flange 14 are a plurality of slots 18, which are placed at even intervals (typically 1 inch) along the entire length of each vertical flange 14.

The prior art does not permit the placement of metal studs in increments less than the increment between the slots. For example, in a track with a 1 inch increment between the slots, two metal studs could not be placed at a distance of 12.5 inches. Further, the prior art provides no direction or aid to rapidly identify precisely where a metal stud ought to be placed during assembly. Finally, the prior art is shipped out in standard material pieces, requiring track members and stud members to be cut to size onsite. For example, if track material came in 16 foot increments, and two 10 foot track members are required, two standard pieces need to be cut resulting in two wasted scrap lengths of 6 foot.

Referring now to the present invention, FIG. 2 illustrates the metal wall assembly 20 which contains a floor track member 22, a ceiling track member 24, a plurality of full-length metal studs 26, a plurality of pre-cut metal studs 28, and a plurality of pre-cut support beams 30. The length of each component is wholly or partially cut in the factory to desired assembly according to an architectural plan.

Each floor track member 22, ceiling track member 24, and pre-cut support beam 30 have indent portions 32 located where either a pre-cut metal stud 28 or full-length metal stud 26 is to be assembled. The floor track member 22 and ceiling track member 24 may be identical, or may differ in the placement of the indent portions 32.

Each floor track member 22, ceiling track member 24, pre-cut support beam 30, full-length metal stud 26, and pre-cut metal stud 28 may have on them a label 34 stating the job name and other unique information. Further, the assembly may contain additional mating labels 36 at the end portions of each full-length metal stud 26, the pre-cut metal studs 28, and near the indent portions 32.

FIG. 3 illustrates a track member 40 having two end portions 42, a pair of vertical flanges 44, and a web 46, all forming a general “U” shaped structure. Each vertical flange 44 contains at least one pair of circular indent portions 48 which are oriented to the interior of the “U” shape, and each circular indent portion 48 contains a circular slot 50. The track members 40 are provided to mount onto a floor or ceiling while supporting metal studs seated with circular indent portions 48 in the wall assembly, in accordance to an architectural plan along the vertical flange 44.

FIG. 4 illustrates one embodiment of a metal stud 60 which contains two end portions 62, a pair of vertical flanges 64, a web 66, and a pair of returns 68. Each vertical flange 64 contains a pair of elongated dimple portions 70 which are oriented to the interior of the metal stud 60, each creating an external cavity designed to seat with an indent portion of a track member. The length “L” of the metal stud 60 and locations of the elongated dimple portion 70 are provided from an architectural plan.

While in some embodiments an elongated dimple portion 70 is located within each end portion 62, the main body of the metal stud 60 may also contain any number of elongated dimple portions 70.

Each elongated dimple portion 70 creates a substantial depression in the outside surface of the vertical flanges 64 designed to accept and seat with the indent portions of a track member. Each elongated dimple portion 70 contains a flat, constant surface 72 attached to a vertical flange 64 via a deformed portion 74. The deformed portion 74 may create either rounded or sharp corners inside the elongated dimple portion 70.

FIG. 5 illustrates another embodiment of a metal stud 80 which contains two end portions 82, a pair of vertical flanges 84, a web 86, and a pair of returns 88. Each vertical flange 84 contains slotted dimple portions 90 located within the end portions 82. The length “L” of the metal stud 80 is directly translated from an architectural plan prior to assembly.

Each slotted dimple portion 90 is oriented into the interior of the metal stud 80, creating a substantial exterior depression designed to accept and seat indent portions of the present invention. Each slotted dimple portion 90 contains a substantially flat portion 92 attached to vertical flange 84 via a round or sharp deformed portion 94. Slot 96 is located within the flat portion 92, and the slot 96 may be in some embodiments sized to act as a receptacle for a screw or other fastener. In other embodiments, the slot 96 is large enough to cover flat portion 92, or the slot 96 is small enough to be a pilot hole for an associated fastener.

FIG. 6 illustrates a segment of a package assembly 100. Each pre-cut metal stud 110 contains two pairs of circular dimple portions 114, located on the end portions of each metal stud 110. The pre-cut metal studs 110 are attached to each other via a nip 112 which is of such a size that the nip 112 can be broke by bending and twisting each metal stud 110 without tools.

The package assembly 100 and nip 112 are formed by partially cutting into a standard piece of metal stock on both sides of the apparatus at a desired location along the lateral length “L” in accordance to an architectural plan. The cut is illustrated with a certain thickness for purposes of clarity, but it is to be appreciated that the cut may be substantially thinner or thicker. A circular dimple portion 114 is formed on either side of the cut and the end portions of the entire assembly. In this manner, any number of precut metal studs 110 may be formed at varying desired lengths out of the same standard stock while remaining attached to each other to facilitate shipping and handling.

In one embodiment, the package assembly 100 contains some metal studs having a length “A” and other metal studs having a length “B”. “A” and “B” may be of equal value, while in other embodiments “A” and “B” will have different values. FIG. 6 may also be part of a larger package with pattern of “pre-cut stud 110, nip 112, pre-cut stud 110, nip 112.” A similar pattern of cuts may also be made with the track member of FIG. 3.

FIG. 7 illustrates an attachment point 120. The two pre-cut studs 124 each contain at least one pair of circular dimple portions 126, each circular dimple portion 126 containing a circular slot 128. While a circular dimple portion 126 is illustrated, other embodiments may have dimple portions elongated with or without a slot.

Each pre-cut stud 124 is attached to the other via the nip 130. The nip 130 is of such a size that the nip 130 can be broken by bending and twisting each metal stud 124 connected to the nip 130 without tools.

FIG. 8 is a front view of a metal stud 140, highlighting the depth of the dimple portions 142. The metal stud 140 contains a web 144, two vertical flanges 146, and two returns 148. Each dimple portion 142 forms an exterior cavity 150 in the vertical side 146. While each dimple portion 142 is illustrated as tapering inwardly 152 to form a flat portion 154, the dimple portions can take any form or shape with the exterior cavity 150 of sufficient depth to nest with a desired indent portion in a track member.

FIG. 9 illustrates a selectively slotted track member assembly 160 comprised of two vertical flanges 164, a web 166, and at least one pair of slots 168. Between each pair of slots 168 is a metal stud 170 fastened to a track member 162 by a fastener 172 positioned through each slot 168.

Each pair of slots 168 are placed in a pre-determined location along the length of the vertical flanges 164. There may be any number of pairs of slots 168. The studs may be placed exactly where they are desired according to an architectural plan.

The interaction between the metal stud 170, track member 162, and fastener 172 of FIG. 9 is illustrated in FIG. 10, which shows a cutaway view of a fastener assembly 180. A fastener 182 with a screw point 184, smooth portion 186, and head 188 is holding together the stud wall 190 and track member 192 in constant contact. The smooth portion 186 of the fastener 182 is placed within a slot 194, and the screw point 184 is drilled into the material of the stud wall 190. In this fashion, the fastener 182 and stud wall 190 may move up and down within the slot 194, with movement bounded by the dimensions of the slot 194.

FIG. 11 illustrates a metal stud seating assembly 200 with track member 210 containing two vertical flanges 212, a web 214, and at least one pair of circular indent portions 216 located within each vertical flange 212. The circular indent portions 216 may deform the vertical side flange 212 inwardly to such an extent as to mesh within the elongated dimple portion 218 of the metal stud 220.

The metal stud seating assembly 200 is created by placing the metal stud 220 into the track member 210 such that the end portion of the metal stud 220 causes the vertical flanges 212 to flex and snap back into position as the circular indent portion 216 seats inside the elongated dimple portion 218. The metal stud 220 then may be moved vertically when the metal stud 220 is seated with the track member 210. Optionally, a fastener may be inserted through the slot 222 located within the circular indent portion 216 when the metal stud 220 is seated.

FIG. 12 illustrates another embodiment of a metal stud seating assembly 240. A track member 242 consists of a web 244 and two vertical flanges 246 each having at least one elongated indent portion 248. Each elongated indent portion 248 has a slot 250 located within the flat portion 252. The metal stud 254 has its own associated pair of elongated dimple portions 256, designed in such a way that they nest with the elongated indent portions 248.

The elongated indent portions 248 are placed at a specific point down the length of the vertical flanges 246 as taken from an architectural plan of the wall assembly. The location of the pair elongated indent portions 248 correspond with the desired location of the metal stud 254.

FIG. 13 illustrates another embodiment of a metal stud seating with a track member in a joint assembly 260. A track member 262 consisting of a web 264, a pair of vertical flanges 266, at least one pair of elongated indent portions 268, and at least one pair of circular indent portions 270 is seated with a metal stud 272. Both the elongated indent portions 268 and circular indent portions 270 may exist in any number and both are placed in precise locations down the length of the vertical side wall 266, those locations corresponding to an architectural plan.

The metal stud 272 contains a pair of elongated dimple portions 274 designed to seat or mesh with either the elongated indent portions 268 or circular indent portions 270. The metal stud 272 when seated with the track member may move up and down in the vertical direction, the movement bounded by the boundary interaction between the elongated dimple portions 274 and either the elongated indent portions 268 or circular indent portions 270. In that manner, the location of the indent portions provides a precise installation location while enabling vertical movement to adjust for working conditions or measurement errors. By electing to place either an elongated indent portion 268 or a circular indent portion 270, the range of vertical adjustment by the seated metal stud 272 may be precisely adjusted.

The architectural plan also provides the general attributes of the wall (e.g., length, height, doors, windows, outlets, utility pipes, etc.). From the architectural plan, the necessary measurements (e.g., length, width) for each piece of the metal wall frame can be extrapolated. Indent portions and dimple portions may be placed on the metal studs and track members in precise locations in accordance with the architectural plans. A cut may be made substantially through a piece of metal stock, creating specific lengths of metal studs and tracks as desired. The cut goes partially through the stock, leaving a small nip of material which permits the stock piece to be shipped as a whole and then broken into the smaller desired pieces by hand. In this manner, large single pieces may be bundled with small still attached pieces forming an integrated piece substantially the same size as the long piece. By enabling the shipping of small and long pieces in the same bundled dimensions, cost savings and efficiency may be achieved.

While certain embodiments have been described, it must be understood that various changes may be made and equivalents may be substituted without departing from the spirit or scope of the present disclosure. Within the embodiments described, it is also to be understood that the features and characteristics disclosed are interchangeable with other embodiments. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from its spirit or scope. 

What is claimed is:
 1. Wall assembly comprising: track members each having a web portion and flange portions, with indent portions at selected increments along at least one flange portion of each track member, a plurality of wall studs each having end portions to engage the track members and dimpled portions adapted to engage the flange portions of the track members, and each wall stud having flange portions oriented to engage the flange portions of the track members with the dimpled portions nested with the indent portions in the track members at the end portions when assembled.
 2. The wall assembly as claimed in claim 1 comprising in addition: at least some of the dimpled portions on the studs are slotted to provide for adjustment of the stud in relation to the adjacent track members and the insertion of fasteners.
 3. The wall assembly as claimed in claim 1 comprising in addition: the studs and the tracks are cut to length and pre-partially cut through to shorter lengths in accordance to an architectural plan of the desired wall assembly but with such shorter lengths maintained in longer lengths so that bundles of such studs can be sent to an assembly location and the pre-partially cut lengths separated for assembly of the wall assembly in accordance with the architectural plan thereof.
 4. The wall assembly as claimed in claim 3 where the studs are cut through the returns with only at least a part web portion of the studs not precut through.
 5. The wall assembly as claimed in claim 2 comprising in addition: the studs pre-partially cut through in shorter lengths in accordance to an architectural plan of the desired wall assembly but maintained in longer lengths so that bundles of such studs can be sent to an assembly location and the pre-partially cut lengths separated for assembly of the wall assembly in accordance with the architectural plan thereof.
 6. The wall assembly as claimed in claim 5 where the studs are cut through the returns with only at least part of web portions of the studs not precut through.
 7. A kit for a wall assembly comprising: track members adapted to be assembled in a wall structure, each haying a web portion and indent portions in at least one flange portion of each track member at locations determined by an architectural plan of a desired assembled wall structure, a plurality of wall studs each haying end portions adapted to engage the track members and with dimpled portions adapted to be assembled and nested with indented portions of the track members in accordance with the architectural plan, and each stud haying flange portions oriented to engage flange portions of track members of the wall assembly with dimpled portions adapted to nest with indent portions in the track members when assembled in accordance with the architectural plan.
 8. The kit for a wall assembly as claimed in claim 7 where the studs are cut through the returns with only at least a part web portion of the studs not precut through.
 9. The kit for a wall assembly as claimed in claim 7 where in addition the studs are pre-cut to length and pre-partially cut through to shorter lengths in accordance to an architectural plan of the desired wall assembly but maintained in longer lengths so that bundles of such studs can be sent to an assembly location and the pre-partially cut lengths separated for assembly of the wall assembly in accordance with the architectural plan thereof.
 10. The kit for wall assembly as claimed in claim 9 where the studs are cut through the returns with only at least a part web portion of the studs not precut through.
 11. The kit for wall assembly as claimed in claim 8 comprising in addition: the studs pre-partially cut through in shorter lengths in accordance to an architectural plan of the desired wall assembly but maintained in longer lengths so that bundles of such studs can be sent to an assembly location and the precut lengths separated for assembly of the wall assembly in accordance with the architectural plan thereof.
 12. The kit for wall assembly as claimed in claim 11 where the studs are cut through the returns with only at least a part web portion of the studs not precut through. 